PLATEPREP 16.1

USER MANUAL

21.11.2017

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© Copyright 2017

Esko-Graphics Imaging GmbH, 25524 Itzehoe, Germany

All rights reserved. This document and all information and instructions contained within are the property of Esko-Graphics. These documents contain the product descriptions according to their current state at the time of publication, but no responsibility whatsoever is taken for the correctness of this information. No guarantees are granted or expanded upon by this document. Furthermore, Esko-Graphics does not guarantee the illustrations relating to the usage of the products, or for the results from using the software or the use of the information contained herein. Esko-Graphics is not responsible for direct or indirect damages caused by the logical consequences or latent damages which may result from the use of the software, or from the impossibility of software use or of the information contained herein.

The technical data contained herein and the content of this manual are subject to change without prior notification. Revisions which point out such changes and/or supplements may be issued from time to time.

Without express written consent, no part of this document may be reproduced, transferred, electronically stored or published, irrespective of the reasons and irrespective of the method or means used, i.e. electronic, mechanical, by printing, microfilm, etc.

These documents replace all previous versions.

Grapholas® is a registered trademark of Esko-Graphics Imaging GmbH.

Cyrel®, Cyrel® Digital Imaging System and Cyrel® Digital Imager (CDI) are registered trademarks of DuPont.

Microsoft and the Microsoft Logo are registered trademarks of Microsoft Corporation in the USA and other countries.

Esko-Graphics software may include the "RSA Data Security, Inc. MD5 Message-Digest Algorithm".

JDF and the JDF Logo are trademarks of the CIP4-Organisation. Copyright 2001 The International Cooperation for the Integration of Processes in Prepress, Press and Postpress (CIP4). All rights reserved.

Java and all Java-based trademarks and logos are trademarks or registered trademarks of Sun Microsystems in the U.S. and/or other countries.

Some parts of this software use technologies of JGoodies, Barbecue (Copyright 2003, International Barcode Consortium), and Jakarta (licensed by Apache: www.apache.org/licenses/LICENSE-2.0.txt).

All other product names are trademarks or registered trademarks of their respective owners.

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Table of Contents SYSTEM REQUIREMENTS ........................................................................................................................................................ 5

WINDOWS SERVICE AND PORTS ............................................................................................................................................ 6

FIRST START-UP OF THE SOFTWARE ....................................................................................................................................... 7

ENTERING THE LICENSE KEY .............................................................................................................................................................. 7 SETTING THE LANGUAGE .................................................................................................................................................................. 8

MERGER ................................................................................................................................................................................. 9

QUICK START ................................................................................................................................................................................. 9 THE USER INTERFACE ...................................................................................................................................................................... 9 TOOLBAR .................................................................................................................................................................................... 10

Loading Images ................................................................................................................................................................... 11 Displaying Image Data ........................................................................................................................................................ 11 Plate Size and Partial Plate ................................................................................................................................................. 12 Frames and Cutting Lines .................................................................................................................................................... 12 Adding Text ......................................................................................................................................................................... 13 Information on Grids and Image Position ........................................................................................................................... 13 "Step & Repeat" and Seamless Option for Sleeves ............................................................................................................. 14 Mirroring, Inverting, Lenticular, iMask ............................................................................................................................... 14 Output Options ................................................................................................................................................................... 14 Sending a Job to CDI or Creating a TIF File .......................................................................................................................... 15 Displaying the Job List of the CDI ........................................................................................................................................ 16 Cropping and Rotating Images ........................................................................................................................................... 16 Automatic Positioning of the Images .................................................................................................................................. 16 Manual Cropping ................................................................................................................................................................ 17

MENU BAR ................................................................................................................................................................................. 18 Unloading Images ............................................................................................................................................................... 18 Unloading Positioned Images ............................................................................................................................................. 18 Select Working Folder... ...................................................................................................................................................... 18 Saving the Image Arrangement .......................................................................................................................................... 19 Loading the Image Arrangement ........................................................................................................................................ 19 Deleting the Image Arrangement ....................................................................................................................................... 19 Automatic Positioning of the Images .................................................................................................................................. 19 automatically position new images .................................................................................................................................... 19 Removing Images from the Working Surface ..................................................................................................................... 19 Displaying File Names ......................................................................................................................................................... 19

WORKING SURFACE AND STATUS BAR .............................................................................................................................................. 19 DISPLAYING PLATE USE .................................................................................................................................................................. 20 MULTIPLYING IMAGES ................................................................................................................................................................... 21 MANAGING THE PLATE LIST ............................................................................................................................................................ 21

Creating a New Plate .......................................................................................................................................................... 21 Changing the Plate .............................................................................................................................................................. 23 Deleting the Plate ............................................................................................................................................................... 24

TIF OUTPUT ................................................................................................................................................................................ 25 EXPOSING PLATE BORDERS ............................................................................................................................................................. 25 TEMPLATES ................................................................................................................................................................................. 26

Creating a Template ........................................................................................................................................................... 26 Loading a Template ............................................................................................................................................................ 26 Modifying a Template ......................................................................................................................................................... 27 Moving a Template ............................................................................................................................................................. 27

JOB INFORMATION ........................................................................................................................................................................ 27 LOADING IMAGES VIA "DRAG & DROP" ............................................................................................................................................ 28 "UNIQUE ID" .............................................................................................................................................................................. 28

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"IMASK" OUTPUT (OPTION) .......................................................................................................................................................... 29 "LENTICULAR" OUTPUT (OPTION) ................................................................................................................................................... 29 BASIC MERGER SETTINGS ............................................................................................................................................................... 30 MANAGING DATA SOURCES ........................................................................................................................................................... 31

Adding a Local Data Source ................................................................................................................................................ 32 Adding an FTP Data Source ................................................................................................................................................. 32 Changing an Entry ............................................................................................................................................................... 33 Deleting an Entry ................................................................................................................................................................ 34 Saving Settings .................................................................................................................................................................... 34

SETTING THE OUTPUT DEVICES ........................................................................................................................................................ 34 ADJUSTING THE "MERGER" USER INTERFACE ..................................................................................................................................... 35

Password-Protecting Functions .......................................................................................................................................... 36 Changing the Password ...................................................................................................................................................... 37 Entering a Password to Change Settings ............................................................................................................................ 37

CONNECTION TO THE "DEVICE MANAGER" .......................................................................................................................... 38

SETTING UP THE "DEVICE MANAGER" CONNECTION ............................................................................................................................ 38 LOADING THE LEN DATA FROM THE "DEVICE MANAGER" .................................................................................................................... 39

DFS EXPLORER ..................................................................................................................................................................... 40

CHANGING THE VIEW .................................................................................................................................................................... 40 ROTATING, MIRRORING AND DELETING FILES ..................................................................................................................................... 41 DISPLAYING DATA ......................................................................................................................................................................... 41

ACM VIEWER ....................................................................................................................................................................... 42

SIMULATION IN DFS MERGER ......................................................................................................................................................... 42 DISPLAYING INDIVIDUAL CUTTING CHANNELS ..................................................................................................................................... 43 DISPLAYING LEN FILES .................................................................................................................................................................. 43 OVERLAYING MULTIPLE FILES.......................................................................................................................................................... 44 ENLARGING, MOVING AND MEASURING ........................................................................................................................................... 44

CDI MONITOR ...................................................................................................................................................................... 45

SUPPORT.............................................................................................................................................................................. 46

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System Requirements

The following minimum requirements must be met:

Intel Dual Core 2 processor

2 GB RAM

Network board

screen resolution of 1,280 x 1,024 pixels

CD-ROM drive

32-bit operating system

Microsoft Windows XP

disabled firewall

disabled UAC (User Account Control)

FTP server installed and enabled(Only in combination with Grapholas 10.3)

Grapholas 10.3 on the CDI

Grapholas 12.1 on the CDI with Full HD Flexo or Pixel+

The following configuration is recommended:

Intel i7 processor

8 GB RAM

Hard drives: 512 GB SSD

1 GB network board

Microsoft Windows 7 or 10 – 64 bit

disabled firewall and user account control (UAC)

Grapholas 16.1 on the CDI

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Windows Service and Ports

The service for the "Digital Flexo Suite" is started automatically.

The following programs must be enabled:

gravurd

cmotsim

cdid

The Digital Flexo Suite Service "bsl_cdisvc / Esko DFS" and an http server "bsl_http / Esko HTTP" are installed to allow communication with the CDI.

The following ports are used for communication with the CDI:

Port 5542: gravurd (TCP)

Port 5543: cmot (TCP)

Port 5544: cdid (TCP)

Port 5544: cdid (UDP)

Port 5580: http server (TCP)

In the firewall, these ports (in/out) must be released on the DFS as well as on the CDI.

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First Start-up of the Software

LEN and TIF files are prepared for exposure on a CDI using the "Merger". It positions the images on the printing plate, and can also rotate, mirror, crop and invert the images as required.

Several CDIs can be controlled via the network simultaneously.

The "Viewer" is used for viewing and measuring the Len/TIF files. The angle and the rasterization can also be measured.

"iMask" (option) adds an adjustable frame to the output data and creates an additional LEN or TIF file.

"Lenticular" (option) adjusts the width of the job to adapt the data to the lens system for creating 3D images.

All important settings are copied over during an update. When the software is being installed for the first time, the output devices must be set up and the network settings must be set.

Entering the License Key

During initial installation or when updating from an older version, the license key must be entered to start the "Merger":

The ESKO-Service provides a serial number for this "ProductID" which needs to be entered in the "Serial Number" field and confirmed by ENTER. The license can be subsequently changed with the "New License" program in the Windows Start Menu under "Esko - Digital Flexo Suite - System".

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Setting the Language

The language can be changed in the Windows start menu under "ESKO – Digital Flexo Suite - System – UI Language":

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Merger

The "Merger" is used to load the image data from the local hard drive or from the network and to send it to the preselected CDI.

In addition, simple tools such as "mirror", "crop" and "rotate" are available.

Quick Start

1 Start the Merger and load the required images. They are displayed in the image gallery (on the right).

2 If necessary, select the CDI or the TIF output device. All important parameters are updated in the Merger.

3 Position the images on the working surface. Click on the images or the working surface with the right mouse button to display additional information.

4 Select the required plate. Right-click on the plate to display additional information.

5 Send the job to the CDI or the TIF output device.

The User Interface

The Merger can be divided into four areas:

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Area 1: menu bar / toolbar with icons for the most important options

Area 2: working surface on which the images are positioned

Area 3: display of loaded image data

Area 4: status bar - display of the most important settings

Toolbar

All important functions are listed in this area. The toolbar is subdivided into seven areas:

1Opens a dialog box to load the image files.

2 Opens additional functions such as "Bitmap Viewer".

3 Activates additional functions in area 7 to adapt the output.

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4 Allows to set the data output, for example, the drum, the plate and the CDI.

5 Opens an overview of the jobs lined up on the selected CDI.

6 Opens a dialog box to send the job to the CDI or to the TIF output device.

7 Allows to modify the image data, for example, rotating and cutting.

8 Area for the various functions selected in area 3.

If some required functions are not displayed, they can be activated in the Merger configuration settings.

Loading Images

Ctrl + E

calls up a file dialogue box in which the LEN or TIF files can be selected.

1 Selection of network shares.

2 Display of directories.

3 Display of files. By pressing the "Control" or the CAPS button together with the left mouse button, several files can be marked simultaneously; they can then be loaded by pressing "OK". Single files can directly be loaded by double-clicking them.

4Multiple loading of the files.

Displaying Image Data

Opens the "Bitmap Viewer".

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Plate Size and Partial Plate

1Display of the drum circumference – This value can be changed for sleeves.

2Switchover to partial plate – In this mode, the vacuum on the CDI is not analysed and is reduced to a lower, safer speed.

3Allows to set the plate width and plate height in partial plate mode. The data is entered in the format 'width x height' (e.g. 768 x 500).

4Save the newly entered entry or delete an entry from the existing list:

Frames and Cutting Lines

1Allows to enter a frame area which is not available for the imaging process. The area is marked red.

2If activated, cut marks are added in the corners of each image.

3Distance between cut marks and image.

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Adding Text

1 Add text to or delete from all positioned images. A frame is automatically added to all images.

2Allows to switch the position (top or left).

3 Selection of the text size.

4 Input field for the text. The text should not be longer than the image width or height. The position and width of the text is marked in yellow on the working surface. A frame is automatically added to all images.

The text can be deleted by clicking on the "X" at the end of the input field.

5 Addition of an image name together with a date and time stamp.

Information on Grids and Image Position

1Allows to enter the raster count and the angle if they have not yet been included in the image. Images without this information are marked in red on the work surface.

2Allows to mark an image as a test wedge. For this image, the output optimisation function is deactivated to increase productivity. If these two fields are highlighted in grey then they are irrelevant for the selected CDI.

3Allows to display and change the current image position.

4Confirmation of the changed image position. The image is not positioned until the changed image position is confirmed.

5 Activation of the overlaying option. The images can be positioned on top of each other. Using the arrows, the selected image can be positioned above or below another image.

6Allows to display and change the image to make further changes.

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"Step & Repeat" and Seamless Option for Sleeves

1Allows to enter the number of repetitions in horizontal and vertical direction. It is possible to set a gap between the images.

2Displacement of the image above the zero point of the sleeve (5 activated).

3Offset of the images to each other when horizontal repetition is selected (5 activated).

4Predefined offset of the images to each other (5 activated).

5 Activates the seamless option. If the image is smaller than the circumference, a gap will be automatically added and repeated in vertical direction if possible.

Mirroring, Inverting, Lenticular, iMask

If this icon is not displayed, it can be displayed by selecting "Image Manipulation" under "Options - Configuration".

1Allows to mirror (horizontally or vertically) and invert the selected image. "ymir", "xmir" or "inv" is added to the new files.

2 "Lenticular" output settings. For more information, refer to chapter "Lenticular".

3 "iMask" output. For more information, refer to chapter "iMask" Output.

Output Options

1Selection of the drum on the CDI. This option is only shown if more than one drum or the drum and the sleeve have been set up on the CDI.

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2 Selection of the plate. To ensure an optimum imaging result, the right plate needs to be selected. Additional information such as "UV Inline" and "Full HD Flexo" is stored on the plate.

Normal plates are marked with a circle and Inline UV plates are marked with a square.

Using the right mouse button to click the plate entry displays information on the plate properties.

Only the plate types which fit the selected drum are displayed.

For more information, refer to chapter "Managing the Plate List".

3Selection of the required Kongsberg settings. If activated, a yellow bar is visible on the left or on the bottom in the Merger.

The cutting file for the Kongsberg is stored in the directory which was selected for this setting.

For more information, refer to chapter "Kongsberg Output (XL CUT)".

4 Selection of the output device. CDIs and TIF output devices are listed separately.

Sending a Job to CDI or Creating a TIF File

Ctrl + E

opens a dialogue window in which the job name can be entered. By pressing "OK", the job is sent to the CDI or a TIF file is created in the output directory.

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Displaying the Job List of the CDI

displays the job list of the connected CDI. In the "Action" column, the job can be deleted by clicking on the cross. The job status is displayed in the "Status" column. An explanation of the icons can be found in the "Grapholas" user manual.

Cropping and Rotating Images

1 Automatic cropping of the selected images. Unused frame areas are removed.

Right-click the icon to undo the changes.

The distance to the "Bleed" pixels can be set in the Merger properties. If the image contains "Staggered Cut" information, the image is cut on the cutting line.

2 Opens a new window in which the image can be cut. For more information, refer to chapter "Manual Cropping".

3 Rotates the selected images by 90°. The rotated files are generated when sending the data to the output device. Depending on the resolution, this may take some time.

Automatic Positioning of the Images

The images loaded in the Merger can be automatically positioned.

Use the key combination Ctrl + a to reposition all images automatically. Images which were already positioned on the working surface are removed.

Use the key combination Ctrl + h to position all non-positioned images automatically. Already positioned images are not removed.

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When more than one image was marked (Ctrl + left mouse button), only these images are used for automatic positioning.

Images with different resolutions cannot be sent on one plate to the CDI. When multiple resolutions are available for the automatic positioning, a selection is displayed.

Only the images with the selected resolution are then positioned.

You can define in the basic settings of the Merger how to position the images. If the images are to be subsequently cut by hand, then the cut-optimised positioning method is a good choice.

Manual Cropping

opens a new window in which the image can be cropped:

Starting from the frame area, a lasso can be pulled open by pressing and holding down the left mouse button and pulling the mouse across the work surface; or the exact lasso size can be entered in the four input fields on the right-hand side (1).

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The distance between two positions in the image can be measured by pressing and holding the left mouse button down.

Individual sections of the image can be enlarged with a square magnifier by pressing and holding down the left mouse button and pulling the mouse across the section of interest. The magnified image section can then be positioned using the arrow keys on the keyboard.

displays the entire image.

performs the automatic cropping.

sets back all cutting edges.

saves the current image section as a new LEN file.

Manual cropping is not available for LEN files of the "PlatePatcher" and the "Staggered Cut".

Menu Bar

Only the additional functions which are not listed in the toolbar are described. The menu bar is situated above the toolbar.

Unloading Images

"File - Unload Image" (Ctrl + u) removes the selected image from the "Merger". The file is not deleted from the hard drive.

Unloading Positioned Images

"File - Remove All Positioned Images" (Ctrl + d) removes all images from the "Merger" which are positioned on the working surface. The files are not deleted from the hard drive. This is useful when the job was sent and several images are still in the queue.

Select Working Folder...

"File - Select Working Folder" (Ctrl + w) changes the working directory in which all images are copied or moved during the loading process. This option is not available if images are loaded.

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Saving the Image Arrangement

"File - Save Plate" (Ctrl + s) saves the compilation and the exposure parameters as plate. When the compiled images are sent to the CDI, the plate is automatically saved under the entered name.

"File - Save Plate as" saves the compilation under another name.

Loading the Image Arrangement

"File - Load Plate" (Ctrl + L) loads a previously saved or sent compilation with all parameters. All currently loaded images are removed.

Deleting the Image Arrangement

"File - New Plate" (Ctrl + n) removes all images from the "Merger" and resets the parameters.

Automatic Positioning of the Images

"Position - Auto Arrange Images" (Ctrl + a) automatically positions as many loaded images as possible on the working surface. Beforehand, images which were already positioned on the work surface are removed. The type of positioning can be selected in the Merger properties.

automatically position new images

"Position - Auto Arrange New Images" (Ctrl + h) automatically adds the loaded images to the compilation on the working surface. Already positioned images are not removed.

Removing Images from the Working Surface

"Position - Unplace all" (Ctrl + u) removes all images from the working surface. The images are not unloaded.

Displaying File Names

"Windows - Display Names" shows the file names in the images positioned on the working surface.

Working Surface and Status Bar

The working surface shows the available area on the plate. It is not necessary to enter the upper and lower borders as the entire working area is shown.

The loaded images are pulled from the right queue on the working surface by holding down the left mouse button.

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In addition, guides can be pulled from the grey frame area by holding down the left mouse button. The images cannot be positioned in the red area. The guide can be removed again by clicking with the right mouse button on the grey frame area.

Using the right mouse button to click the image file displays information on the image.

The status bar shows the current settings and the number of loaded images.

Displaying Plate Use

Using the right mouse button to click on the work surface displays information on the plate size and the use of the plate.

The line "Partial Plate" shows the values for the marked area. The line "Full Plate" refers to the entire work area.

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Multiplying Images

An image can be multiplied by holding down "Ctrl" on the keyboard and pressing the left-hand mouse button:

This is possible on both the working surface and from the image gallery (right).

Managing the Plate List

Selecting "Edit – Edit Plate List" opens a new window where you can delete, change and create new plates.

"Cancel" aborts the process – no data is changed. By pressing "Quit", the window is closed. "Next" shows the next window.

Creating a New Plate

First select the desired medium "Plate Type" (1), then check "New" (2) and press "Next" (3) to go to the next menu:

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"Plate" – Flexo Plates

"Sleeve" – print sleeve of DuPont and Flint

"Plate on Sleeve" – Flexo plates mounted on a print sleeve

"Steel Base" – metal backing plate for magnetic drum

"Film" – Film

If Grapholas 10.1 or higher is installed on the CDI, a plate database is shown. When the desired plate manufacturer "Brand" (4) or the plate type "Plate" (5) are not available, the option "other" can be selected:

"Name" (7) determines the display name in the plate list and "Thickness" (7) the plate thickness. For sleeves, the circumference is entered in the field "Circumference" (7):

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Additionally, the output in field "Distortion" (7) can be distorted in circumference direction. The input is made as a percentage. If you enter "5.0", the output is enlarged by 5 percent in circumference direction. Entering "-5.0" would downsize the output accordingly.

Under the setting "Manual" (9), enter the values for "Speed" (10) and "Laser Power" (10). The setting "Energy" (9) sets the laser energy "Laser Energy" (10) and speed and performance are selected automatically according to the resolution:

With Inline UV, enter the values "UV Main Exposure" (13) and "UV Main Energy" (13) for the front exposure and with automatons, enter the values "UV Back Exposure" (14) and "UV Back Energy" (14) for the back exposure. You can disable the UV exposure by checking "No UV" (12).

UV2 exposure parameters are specified in section "Full HD UV Parameters" (14) when the CDI has been prepared for Full-HD Flexo.

"Finish" (16) saves the plate.

Changing the Plate

First select the desired medium "Plate Type" (1), then check "Edit" (2) and press "Next" (3) to go to the next menu:

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After setting the desired "Plate" (4), you can change all parameters except for the plate name. "Next" opens the next menu.

Deleting the Plate

First select the desired medium "Plate Type" (1), then check "Edit" (2) and press "Next" (3) to go to the next menu:

The desired plate "Plate" (4) is set and removed by pressing "Remove" (5).

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TIF Output

"Edit – Edit Device List" opens the dialogue window to subsequently add new TIF output devices (special license required):

"New" in section "Other Devices" opens a new dialogue box in which you can enter the name of the TIF output device.

Width and height can be set in the fields "Width" and "Height".

"Negative" inverts the background colour for the output on film. The output directory is defined in field "TIF Target Folder".

"Remove" deletes the selected entry.

"Expose" creates the TIF file.

Exposing Plate Borders

The "Expose frames" option can be activated in the basic settings of the "Merger" under "Edit – Preferences…", giving the plate more stability in the washer.

The left and the right border can be set in the "Drum Window" and is now shown in white. When the TIF output is negative, the border is displayed in black.

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Templates

If these functions are not displayed, they can be activated in the basic settings.

The positions, image sizes, image resolution and plate parameters are stored in the template in order to position images quickly at a later time. This working mode is interesting for register pinwheels such as, e.g. for Letterpress.

Creating a Template

To create a template, you first position the required images onto the working surface and then select the plate type. This compilation is then saved by pressing "Template - Save Template".

Loading a Template

"Template - Use Template" loads the template. This is only possible when no other images are loaded in the "Merger".

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The stored positions and sizes are shown as yellow fields. After loading the images, they can be positioned in the yellow fields.

The images must be within a certain size tolerance in order to be assigned to a field.

Modifying a Template

After loading the template and positioning all the images, the mask can be opened using "Template - Edit Template". Now you can change all parameters as required and save them using "Template - Save Template".

The modified template can now be loaded using "Template - Use Template".

Moving a Template

"Template - Correct Template" opens a new program in which the template can be loaded using "File – Load Plate".

The position of single or multiple images can be changed horizontally using "Across" and vertically using "Circumference". The value is entered absolute or relative to the current position, ENTER is then pressed and the value is set using "Set Position".

Several images are marked by pulling a square around the required images with the left mouse button pressed.

The template is saved by clicking the "Save" button.

Job information

An HTML or XML file with the respective job name is created in the "HTM Target Folder" output directory for each sent job.

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All important information concerning the job is stored in that directory. The output directory "d:\files\output\html" is preset.

Loading Images via "Drag & Drop"

Image files (LEN and TIF) can directly be dragged into the right image bar of the "Merger" from the Windows Explorer. First, the data is copied into the working directory, then it is loaded. If the "Ctrl" key is pressed at the same time, the data is always copied.

"Unique ID"

All LEN and/or TIF files from an AE12 system contain a unique code which can be read by the Merger.

As soon as the "Unique ID" option is activated under "Options – Configuration", this code is added to all images.

Depending on the output, the code is either inserted at the top or in the left frame area as normal text or, for XL CUT, it is output as front text or back text.

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"iMask" Output (Option)

As soon as "iMask" output is activated, a LEN or TIF file with the mask is generated in addition to the job. An appropriate license is required to output TIFs. Depending on the settings, a frame is added to the contour compiling the various elements.

The output directory and the parameters can be changed under "Edit – Edit Mask Output":

"Workflow": Displays the name of the parameter set.

"Mask Export Folder": Output directory.

"Frame": Size of the extension frame.

"Resolution": Output resolution.

"Apply to White": White pixels are expanded.

"Tiff Output": Activates the TIF output.

"Negative": Inverts the output.

"Mirror": Mirrors the output.

Changes are saved by pressing "Save". "New" creates a new parameter set. "Remove" removes the currently selected parameter set. "Close" closes the setup window.

"Lenticular" Output (Option)

As soon as the "Lenticular" function is activated, the output is converted into the required resolution and then sent to the CDI. To achieve an optimum printing result, the output is reprocessed on the CDI.

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1 Activates the "Lenticular" function.

2 Allows to enter a new resolution. This value may differ from the original resolution of the positioned images by a maximum of 50 DPI.

3 Allows to set the number of lenses used for printing.

To ensure an optimum printing result, the correct number of lenses needs to be set.

The resolution results from the test print and the resulting change in the size of the image which is set via the new resolution.

The "Lenticular" output must not be used for normal jobs.

Basic Merger Settings

The basic settings of the Merger can be changed via the menu item "Options – Preferences…":

"Units" switches between "mm" and "inch".

"Digits" and "Post colon" set the amount of numbers and/or decimal points.

"Check Images before start" checks the images of all outgoing jobs.

"File copy method" sets the behaviour while loading images. With the setting "Copy", the files are always copied; if "Move" is selected, they are deleted from the source directory.

"Bleed" sets the border during automatic cropping.

"Expose frames": When activated, the left and right border is exposed to provide more stability to the plate in the washer.

"Show Ruler" activates or deactivates the ruler.

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"Font" changes the font type for text in the bitmap output files. All fonts installed in Windows are available for selection. OCR fonts must be additionally installed:

When restarting the "Merger", "Autoload Job" actuates automatic loading of the last job.

"Archiving Interval:" determines the number of days after which the HTML overview files and the files of the directory "Mergelog" are archived in a ZIP file.

"Disc-Space Warning": The Merger warns the user as soon as the drives being used indicate that their available disc space has fallen below the set value.

"JDF Server": Enter IP number or computer name of JDF server.

"Autoplace mode:" sets the method (mode) of how the images are automatically arranged on the working surface. The fast, space-optimised and cut-optimised methods are available.

In most cases, the fast positioning method is sufficient. The space-optimised method will continue trying to position the images until the maximum time "Timeout" is reached. The cut-optimised method places the images so that the plates can be subsequently better cut by hand.

"Auto Rotate" activates the rotation during automatic positioning to save more space.

In the "Folder" window, the preset output directories can be changed.

The job information is saved in the "HTM Target Folder" directory.

Under "Plugins", the minimum size for "Microcross" and "Centerline" images can be entered. The images are automatically enlarged to this size.

The "Merger" must be restarted after any change.

Managing Data Sources

The image data can be loaded from the local hard drive, by means of a network release, or by FTP. Transmission using FTP protocol is generally more secure than using a network release.

The path entered during installation for the "User Data" is already released as a network drive. Additional data sources can be set up under "Edit – Data Source".

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Adding a Local Data Source

Local data sources can be located on the hard drive of the computer or accessible in the network via "share" function.

The name of the data source "Drive Name" (3) will be shown later in the load dialogue.

"Disk" and "Sub Folder" (6) designate the drive letter and the directory containing the data.

Clicking "Test" (7) opens a new window with the data source set up. "Finish" (9) completes the process. You can always switch to the previous page by pressing "Back".

Adding an FTP Data Source

The FTP server of the data source requires a virtual directory. For a detailed installation manual, refer to "Digital Flexo Suite 101 Installation".

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The name of the data source "Drive Name" (3) will be shown later in the load dialogue.

Enter the IP address or the network name in the field "Host" (6). If the FTP server was installed as specified, enter the "User-Name" (7) and the "Password" (7) as shown in the illustration.

"Disk" and "Sub Folder" (9) designate the virtual drive and the directory containing the data. Should no virtual directory be available, leave the "Disk" field empty.

Clicking "Test" opens a new window with the data source set up. "Finish" completes the process. You can always switch to the previous page by pressing "Back".

Changing an Entry

The settings of the data source can be subsequently changed.

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After selecting the "Drive" (3), you can change the following settings.

Deleting an Entry

After selecting the "Drive" (3), you can remove it by pressing "Remove" (4).

Saving Settings

When you terminate via "Quit", a new window opens requesting whether you want to overwrite the current settings.

Pressing "OK" saves the current settings.

Setting the Output Devices

If no output device such as, e.g., a CDI has been set up yet, the "Edit Device List" window in which you can define various output devices is displayed when the "Merger" is started for the first time.

"Edit – Edit Device List" opens the dialogue window to subsequently add new or delete output devices:

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A TIF license is required in order to create TIF output devices!

"New" in section "Hosts" opens a new dialogue box in which you can enter the IP address or the computer name of the CDI. Press "OK" to search for the CDI on the network.

"Scan Network" scans the network 60 seconds for CDIs and then displays them in a list. A new connection can be selected from this list.

"Accept" accepts the new CDI.

"Test" checks the connection to the CDI.

"New" in section "Other Devices" opens a new dialogue box in which you can enter the name of the TIF output device. Width and height can be set in the fields "Width" and "Height". "Negative" inverts the background colour for the output on film. The output directory is defined in field "TIF Target Folder".

"Remove" deletes the selected entry.

If an old CDI SUN computer is to be connected, you must enter the IP address "127.0.0.1". In addition, service needs to adapt the LEN output format for the SUN.

Adjusting the "Merger" User Interface

The user interface and some of the functions of the "Merger" can be customised and protected with a password ("Edit – Configuration"):

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Password-Protecting Functions

Left-clicking on "Enter Password" opens a new window in which the password is entered twice and confirmed with "Close":

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Changing the Password

Left-clicking on "Change Password" opens a new window in which the current password is entered once and the new password is entered twice. "Close" confirms the input:

Entering a Password to Change Settings

Left-clicking on "Unlock" opens a new window in which the current password is entered. "Close" confirms the input and enables the input mask:

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Connection to the "Device Manager"

The "Device Manager" is part of the "Automation Engine 16". As soon as the Merger is connected to the "Device Manager", the "Merge Queues" are displayed and LEN files can be loaded and jobs can be sent to the CDI via the "Device Manager".

The CDIs are connected in the Device Manager and the corresponding plate lists and functions are read.

LED files are stored in the "Merge Queues". Each queue must be assigned to a plate entry.

A queue can contain various "Image Groups". One Image Group comprises images, which can be used together. This depends on the resolution of the exposure technology, such as Pixel+ or Full HD Flexo.

Setting up the "Device Manager" Connection

The computer name or the IP address of the "Device Manager" is entered in the "Merger" options "Options – Preferences" in the "Workflow-Server" field.

The Merger must be restarted for the Workflow-Server to connect.

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Loading the LEN Data from the "Device Manager"

As soon as the Merger has connected to the "Device Manager", the window colour of the Merger will change and the window name will change from "Merger File Mode" to "Merger AE Manual Mode".

Pressing the button for the load dialogue displays the predefined Device Manager queues ("Merge Queues").

"Load Selected Image Group" loads the selected Image Group. The LEN data contained per Image Group are displayed under "Images".

The complete list can be filtered according to certain image names at the bottom right.

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DFS Explorer

The "Len Explorer" is an add-on product used to display LEN, TIFF and ACM files. In addition, LEN and TIF files can be directly drawn from the "DFS Explorer" into the Merger or the PlatePatcher via drag & drop.

1 menus for additional functions

2 file reread

3 display and selection of the folder

4 display filter

5 Changing the View

6 file preview

Changing the View

The slider can be used to change the view from detail (far left) to large preview (far right).

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In the detailed view, a left mouse click on the respective field sorts the table by name, date, width, height, resolution or file size.

Rotating, Mirroring and Deleting Files

In the DFS Explorer, several files can be selected and rotated, mirrored or deleted with a right mouse click.

Displaying Data

Double-clicking the file opens the Bitmap viewer for LEN or TIFF files and the ACM viewer for ACM files.

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ACM Viewer

This program is used to display and control the output files which were created by using the Digital Flexo Suite. In addition, LEN files are displayed with the cuts (Staggered Cut, Line Editor, etc.) that they contain.

After the Digital Flexo Suite installation, all output files are automatically linked to the "ACM Viewer" .

Simulation in DFS Merger

Simulation of the cutting job is started in the "Merger" with Ctrl+R. All output files are generated and superimposed on top of one another in the ACM Viewer:

1 Content of the active directory

2 Loaded files with the cut contours they contain

3 Information on the loaded files

4 Adjustable line thicknesses

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Displaying Individual Cutting Channels

An individual cutting channel can be selected for display in the "LAYER" section. Additionally holding down the Ctrl button on the keyboard allows multiple channels to be selected:

The LEN file is displayed with the selection "Image".

Displaying LEN Files

When the ACM Viewer is opened, the LEN files can also be displayed. Cutting information is stored in some LEN files, which is displayed under "LAYER":

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Overlaying Multiple Files

By holding down the "Ctrl" button on the keyboard, multiple files can be displayed at the same time in the active directory.

LEN files from the Merger which were created with a cutting file contain a minimum of two register marks. In order to verify the correct cut, the correct register must first be checked.

By holding the "Ctrl" button on the keyboard, you can move the contour of the ACM with the left mouse button until both register marks are above each other. Only the cutting file is moved.

Enlarging, Moving and Measuring

The display can be enlarged and reduced with the mouse wheel. Holding down the left-hand mouse button moves the content.

The measuring function is activated by pressing the right-hand mouse button at the point to be measured. The distance and angle to the current mouse position are now displayed permanently.

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CDI Monitor

The CDI monitor displays the current job, the status and the remaining time for the current imaging processes of the CDIs in the network: In addition, the next jobs are also displayed with the width:

The CDI status is displayed with the following colours:

grey: CDI or service is not activated

red: CDI is activated and is waiting for jobs

green: CDI is exposing a plate – the remaining time is displayed.

The CDI list of the Digital Flexo Suite is used automatically. Right-click on the CDI monitor to change CDI list under "Preferences".

"Fullscreen" displays the monitor as full screen. "Widget" removes borders and the monitor will always be displayed in the foreground.

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Support

Contact information can be found on www.esko.com.